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July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Section 652 (Power Transfer Unit (Service Information) - MK): Assembly

WARNING: This page is about a different car, the 2017 Jeep Patriot and 2017 Jeep Compass. However, it is still accessible from the selected car via links, so may be relevant.
GC0084412Courtesy of CHRYSLER GROUP, LLC
  1. Install output side spool shaft bearing using Installer (special tool #C-3095-A, Installer, Bearing).
    GC0084413Courtesy of CHRYSLER GROUP, LLC
  2. Install ring gear side bearing using Installer (special tool #8148, Cup).
    GC0084409Courtesy of CHRYSLER GROUP, LLC
  3. Install the ring gear.
    GC0084408Courtesy of CHRYSLER GROUP, LLC
  4. Install the new  ring gear bolts and tighten to 74 Nm (55 lbf-ft.).
    GC0084414Courtesy of CHRYSLER GROUP, LLC
  5. Install the carrier case seal using Installer (special tool #9851, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
    GC0084407Courtesy of CHRYSLER GROUP, LLC
  6. Install the shim (3) under the bearing cup (1) in the case side.
  7. Install the bearing cup by hand.
    GC0084415Courtesy of CHRYSLER GROUP, LLC
  8. Install the inner seal into the PTU cover using Installer (special tool #9852, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
    GC0084416Courtesy of CHRYSLER GROUP, LLC
  9. Install the outer seal into the PTU cover using Installer (special tool #9853, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
    GC0084405Courtesy of CHRYSLER GROUP, LLC
  10. Install the shim (1) under the bearing cup (3).
  11. Install bearing cup by hand (3).
    GC0084401Courtesy of CHRYSLER GROUP, LLC
  12. Install the carrier assembly into the case
  13. Install the side cover
  14. Tighten side cover bolts (1) to 23 Nm (17 lbf-ft.).
    GC0084417Courtesy of CHRYSLER GROUP, LLC
  15. Install the output shaft head bearing on to the pinion shaft using Installer (special tool #9714, Installer, Bearing) and a Press.
    GC0084418Courtesy of CHRYSLER GROUP, LLC
  16. Install the output shaft head bearing cup using Installer (special tool #6061, Installer, Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
    GC0084419Courtesy of CHRYSLER GROUP, LLC
  17. Install the output shaft tail bearing cup using Installer (special tool #9855, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
    GC0084394Courtesy of CHRYSLER GROUP, LLC
  18. Install the output shaft spacer onto the output shaft.
    GC0084420Courtesy of CHRYSLER GROUP, LLC
  19. Install output shaft into output shaft housing.
  20. Install output shaft tail bearing on to out put shaft using Installer (special tool #L-4411, Installer, Bearing).
    GC0084391Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The output shaft nut is a staked type nut.

  21. Install the output shaft nut (1) onto the output shaft (2).
    GC0084421Courtesy of CHRYSLER GROUP, LLC
  22. Tighten the output shaft nut using Pinion Nut Socket (special tool #9921, Wrench, Pinion Nut) to 150 Nm (111 lbf-ft.).
  23. Using an inch pound torque wrench check and Pinion Nut Socket (special tool #9921, Wrench, Pinion Nut) (1) check the rotating torque, it should be 30 lbf-in. Add 0.002 in. larger shim to increase rotating torque and add 0.002 in. smaller shim to decrease rotating torque. Repeat until proper turning torque is obtained.
  24. Using a punch stake the output shaft nut.
    GC0084390Courtesy of CHRYSLER GROUP, LLC
  25. Install the pinion housing O-ring (3).
  26. Install the pinion housing shim (1).
    GC0084422Courtesy of CHRYSLER GROUP, LLC
  27. Install the output shaft seal using Installer (special tool #9851, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
    GC0084388Courtesy of CHRYSLER GROUP, LLC
  28. Install a new  extension housing O-ring.
    GC0084389Courtesy of CHRYSLER GROUP, LLC
  29. Install the output shaft housing and bolts onto the carrier housing.
  30. Apply pattern check grease to the ring gear.
    GC0084423Courtesy of CHRYSLER GROUP, LLC
  31. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).
    GC0084387Courtesy of CHRYSLER GROUP, LLC
  32. Install the extension housing and bolts.
  33. Tighten output shaft housing bolts to 38 Nm (28 lbf-ft.).
  34. Tighten the extension housing bolts to 38 Nm (28 lbf-ft.).
    GC0084424Courtesy of CHRYSLER GROUP, LLC
  35. Clean cover and apply MOPAR® axle RTV or equivalent.
  36. Install the vent and bolts, tighten the bolts to 23 Nm (17 lbf-ft.).
    GC0084425Courtesy of CHRYSLER GROUP, LLC
  37. Install the vent shield and bolts. tighten the bolts to 23 Nm (17 lbf-ft.).
    GC0084426Courtesy of CHRYSLER GROUP, LLC
  38. Clean cover and apply MOPAR® axle RTV.
  39. Apply MOPAR® lock AND seal adhesive or equivalent to bolts.
  40. Install the inspection cover and bolts. tighten the bolts to 23 Nm (17 lbf-ft.).
  41. Fill the PTU. Refer to STANDARD PROCEDURE .
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